Difference between Polyester Filament and Polyester Staple fiber production process

Polyester staple fiber vs Polyester filament yarn

In the present day, Polyester is commonly used in the textile industry, which is divided into two types: polyester staple fiber and polyester filament yarn. The major differences between polyester staple and polyester filament yarn are length, classification and characteristics.

The first difference between polyester staple fiber and polyester filament yarn is length. Although polyester staple fiber is short fiber, the length varies from a few centimeters to 10 centimeters. On the other hand, polyester filament yarn is a continuous fiber with a long yarn that starts from 1,000 meters winding into a group.

In addition, there are differences in classification.

Polyester staple fiber is primarily used in spinning to produce spun yarn, while polyester filament yarn is divided into three categories.

  1. Pre Oriented Yarn (POY) is straight-oriented and is used in post-processing production to produce stretch fibers such as Drawn Textured Yarn.
  2. FDY (full draft yarn) and Fully Drawn Yarn (FDY) are primarily used as weft and weaves for making high-strength fabrics and textiles. However, FDY can also be knitted or woven with other filament yarns to produce various fabrics.
  3. Drawn Textured Yarn (DTY) has the advantages of short flow and high-efficiency good quality. Three combinations of intermingling points are Non-Intermingle (NIM), Semi-Intermingle (SIM), and High-Intermingle (HIM).

Definition of Polyester Staple Fiber​

Polyester Staple Fiber (PSF) is produced from fibers of a specific or defined length that are blended or integrated in pure form or with other fibers.

PSF finds applications in various household items including carpets, home furnishings, and clothing.

Polyester Staple fiber production process

The base material, which comes in chips, is melted in an extruder before being quantified in a gear pump and transferred to a nozzle. Polymers that pass through the nozzle are cooled and solidified in a spinning tank, and end up in a fiber form (semi-finished product). Fiber released from multiple spinning tanks is lubricated and gathered before being wound by a gear wheel and placed in cans. Fiber placed in cans is given various properties through a stretching process, in which fiber is stretched at various roller speeds designed to endow different degrees of rigidity and elasticity.

The fiber is again lubricated for enhanced quality and to facilitate the processes that follow. A crimping process takes place to give the fiber various properties, including bulk and mixability. Moisture and lubricant on the fiber is dried off in a heat dryer. The fiber is then cut into required lengths and end up in a bale form. The fiber is then compressed, packaged, and stored for factory release when ordered.

Definition of Polyester Filament

Polyester filament is a durable continuous fiber known for its strength and versatility. DTY textured filament (draw textured yarn) is produced through the processing of POY (partially oriented yarn) and undergoes stretching and crimping processes to enhance the yarn’s strength, volume, and softness.

This material has a variety of applications including fabrics, knits, apparel, ribbons, labels, sporting goods, decorative items such as cushions and duvets, tennis fabrics, car seats, and zippers.

Polyester Filament production process

Dried chips are melted in an extruder before being quantified in a gear pump and transferred to a nozzle. Polymers are pushed through the tiny holes in the nozzle by heat and pressure, resulting in fiber, which is then cooled by cold air or water.

A single filament of mono filament is stretched to achieve various rigidity and elasticity. Stretching takes place at various roller speeds.The filament is then heat-treated to seal in the properties. Set amounts of filament are wound around bobbins and packaged. During packaging, a quality inspection takes place to set aside defective products.


As part of the Polyester value chain, we manufacture Purified Terephthalic Acid (PTA) by oxidizing Paraxylene (Px). From there we make Polyethylene Terephthalate (PET) by combining PTA with Monoethylene Glycol (MEG). Finally we transform recovered PET bales into recycled PET (rPET) flake and pellet.

Polyester Value Chain

Non-woven production process

Step 1: Choice of material: Nylon, Polyester, Polyolefin (PE/PP, PE/PET), Polypropylene

Step 2: Web formation: Carding, Air laid, Wet laid (Spunbond, Melt Blown, Flash spun)

Step 3: Web bonding: Needle punch, Spunlace, Thermal bond, Hot air-throught bond (Chemical bond, stitch bond)

Step 4: After treatment: Dyeing, Treatment

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VNPOLYFIBER Hollow Conjugated Siliconised Fiber

We are Vietnam’s leading exporter in recycled polyester staple fiber, hollow fiber, solid fiber, spinning fiber since 2017 and we have been exporting to more than 30 countries serving more than 200 customers with their strong presence in USA, Canada, China, Brazil, Mexico, Western Europe, and various other countries.  Our polyester staple fiber products are trusted internationally for world class quality. We pride ourselves on our proven ability to consistently deliver high quality products and reliable customer services. 


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